Manufacturing of components of a vehicle using additive layer manufacturing

ABSTRACT

This relates to a method for manufacturing a shell-like structural component for a vehicle using additive layer manufacturing. In a step of the method, a first material is applied to a region of the shell-like structural component. In another step of the method, the region of the shell-like structural component is heated by a laser beam such that the first material is added to the shell-like structural component. The shell-like structural component comprising the first material is cooled in another step such that an internal stress is generated within the shell-like structural component resulting in a bending of the shell-like structural component. This further relates to a shell-like structural component which is manufactured by a method using additive layer manufacturing.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority of German Patent Application No. 102014 116 938.7, filed 19 Nov. 2014, which is incorporated herein byreference in its entirety.

TECHNICAL FIELD

The embodiments described herein relate to a manufacturing process forcomponents of a vehicle. In particular, the embodiment relates to amethod for manufacturing a shell-like structural component for a vehicleusing additive layer manufacturing, a shell-like structural componentfor an aircraft manufactured by the method and the use of a shell-likestructural component in an aircraft.

BACKGROUND

Other objects, desirable features and characteristics will becomeapparent from the subsequent summary and detailed description, and theappended claims, taken in conjunction with the accompanying drawings andthis background.

Nowadays, there exist many different manufacturing processes formanufacturing structural components of vehicles. Such manufacturingprocesses are in most cases subtractive. For example, subtractiveprocesses are milling, cutting, machining, drilling, etc. Thesesubtractive processes may rely on the principle that a certain part ofmaterial is removed from the component in order to change the contoursor the shape of the component which may be assembled in a later step. Itis also possible to remove material, for example on an uneven surface ofa component, such that a high quality of the surface of the componentcan be achieved. However, subtractive processes may be limited in theirapplication since material is removed from the component. In otherwords, the material can only be removed as long as sufficient materialis left such that the component can still fulfill stabilityrequirements. For example, dents or scratches on surfaces may berepaired by removing a distinct amount of material from the surface suchthat dents or scratches on the surface of the component disappear.

DE 10 2007 015 795 A1 describes a metal-cutting machining process for asemi-finished product having a predetermined shape and at least onemachining surface. In order to protect the surface of the product duringthe process, a foil is affixed on the surface.

DE 10 2007 026 100 B4 describes a method providing a milling tool with acutting depth limiter, where maximum cutting depth of the milling toolis limited by the limiter. Therein, a surface section is milled underguidance of the milling tool by the guiding contour. A machining devicefor machining a laminated composite material at a surface section isalso provided.

SUMMARY

According to a first aspect of the present embodiment, a method formanufacturing a shell-like structural component for a vehicle usingadditive layer manufacturing (ALM) is provided. In a step of the method,a first material is applied to a region of the shell-like structuralcomponent. In another step, the region of the shell-like structuralcomponent is heated by a laser beam such that the first material isadded to the shell-like structural component. In another step of themethod, the shell-like structural component comprising the firstmaterial is cooled such that an internal stress is generated within theshell-like structural component resulting in a bending of the shell-likestructural component. The internal stress may at least be induced in theregion of the shell-like structural component and/or near the firstmaterial which is comprised by the shell-structural component aftercooling. The vehicle may be an aircraft, a car or a rail vehicle.

With this method it is possible that the contour or shape of theshell-like structural component may be adapted in an assembled state,for example if it is assembled in the vehicle. In other words, theinternal stress which is generated within the shell-like structuralcomponent after applying the first material to the shell-like structuralcomponent induces a stress or force that bends the shell-like structuralcomponent such that a certain or predetermined shape of the shell-likestructural component which comprises the first material may be provided.The internal stress may be generated by using different materials forthe shell-like structural component and the first material. For example,the first material may be applied to a surface of the shell-likestructural component or only a part of the surface of the shell-likestructural component. In case the first material is applied to only apart of the surface of the shell-like structural component, it ispossible to induce internal stresses within the shell-like structuralcomponent only in a region around or near the applied amount of firstmaterial on the surface of the shell-like structural component. In thismanner, only a part of the shell-like structural component may bedeformed by the internal stresses. This deformation may appear as abending or twisting of the shell-like structural component. However, thefirst material may be applied to distinct locations on the surface ofthe shell-like structural component in order to induce internal stressesnear these locations such that the mechanical resistance of the regionnear the applied first material is improved.

The material may also be applied to the shell-like structural componentsuch that the first material is located within or inside the shell-likestructural component. In other words, first material may not only beapplied to the surface of the shell-like structural component but alsoinside the shell-like structural component. This may be achieved byproviding a layered structure in which a layer of the first material islocated between parts of the shell-like structural component. Usingadditive layer manufacturing, the different layers may be appliedsubsequently.

When applying the first material to the region of the shell-likestructural component, the first material may be a powder which issupplied to the region of the shell-like structural component by apowder supply unit. This powder may be a metallic or non-metallic powderwhich is, when applied to the region of the shell-like structuralcomponent, heated and/or melted. By melting the first material and apart or a region of the shell-like structural component, a connection orcontinuity between both the first material and the shell-like structuralcomponent may be achieved; e. g. the first material is mixed with and/orfirmly bonded to the region of the shell-like structural component. Forheating or melting the first material and/or the region of theshell-like structural component, different methods may be used, such asselective laser melting (SLM). The heating of the shell-like structuralcomponent and the first material may be provided by a laser beam. Theheating of the region of the shell-like structural component by thelaser beam may be conducted during the application of the first materialto the region of the shell-like structural component. In this manner, itis ensured that parts of the shell-like structural component within theregion are melted when the first material is applied. By melting thefirst material as well as the region of the shell-like structuralcomponent, it is possible that this part or region of the shell-likestructural component may be firmly bonded to the first material suchthat a continuity between the first material and shell-like structuralcomponent is provided.

By cooling the shell-like structural component and the first material,melted parts of the first material as well as the shell-like structuralcomponent may be solidified. After solidification, the internal stresswithin the shell-like structural component is generated. The internalstress being generated after solidification may be limited to theregions where the first material has been applied to the shell-likestructural component. The internal stress provides an enhancedmechanical robustness or resistance in the regions within the shell-likestructural component to which the first material has been applied. Theinternal stress may also generate a bending force that bends theshell-like structural component such that it may adopt a predeterminedform or shape.

The shell-like structural component may be a plate with a curved surfaceor only an even plate with no curvature. However, the shell-likestructural component may be a three-dimensional solid which comprisesseveral materials. The shell-like structural component may bemanufactured from metallic or non-metallic materials. The shell-likestructural component may be a part of a large structural component ofthe vehicle. For example, the shell-like structural component is asidewall panel that comprises a curved or even surface. It is possiblethat the shell-like structural component comprises a thickness ofbetween 5 millimeters whereas its lateral dimensions, e. g. length andwidth, are more than one meter. It should be mentioned that thethickness of the shell-like structural component is equal to or greaterthan 5 millimeters. For example, the thickness is 100 millimeters.However, the lateral dimensions are usually much greater than thethickness of the shell-like structural component. The length and widthmay be measured along the curved or even surface of the sell-likestructural component. Generally, the shell or a shell-like structuralcomponent is a three-dimensional structural element with a smallthickness when compared to other dimensions of the structural element. Aplate is a three-dimensional structural element whose thickness is verysmall when compared with other dimensions of the structural component.However, the shell-like structural component may withstand highmechanical loads, such as a traversing vehicle or passenger.

According to an embodiment, the first material is applied to a pluralityof regions of the shell-like structural component from differentdirections.

This can be achieved by using a multi-direction additive manufacturingprocess. It is possible that the first material is applied fromdifferent directions simultaneously such that the time for producing theshell-like structural component may be reduced and a betteraccessibility to every region of the shell-like structural component isachieved.

According to another embodiment, a bending direction is opposite to adirection of a force which acts on the shell-like structural componentwhen it is installed in the vehicle, wherein the force is generated by acargo unit standing on the shell-like structural component or by cabinair pressure.

The bending which is due to the internal stress within the shell-likestructural component generates a deflection of at least a part of theshell-like structural component. In other words, the shell-likestructural component may be curved such that a convex shape andtherefore a deflection in a direction which is substantially parallel tothe thickness of the shell-like structural component is provided. Thedeflection of the shell-like structural component may be much smallerthan its width or length. The deflection is dependent on the thicknessof the shell-like structural component and/or on the distance betweenthe supports of the shell-like structural component. If the shell-likestructural component is supported by two beams, which will be describedin the detailed description of the figures, the deflection of theshell-like structural component is dependent on the distance between thebeams and on the thickness of the shell-like structural component.Moreover, the force may act on the surface of the shell-like structuralcomponent in a direction which is opposite to the deflection of theshell-like structural component. In this manner, the deflection of theshell-like structural component is reduced. In particular, the bendingof the shell-like structural component by the internal stress isdirected opposite to a load direction which may occur during operationof the vehicle. Such loads or forces may be pressure forces for example.In other words, the force may be generated by a cabin pressure or apressure difference between the cabin pressure and the environmentalpressure during flight of an aircraft. The forces may also be generatedby a mass of a cargo loading unit which is placed on the shell-likestructural component or the dead load of the shell-like structuralcomponent. However, the force may be a gravitational force. The bendingdirection is a direction into which at least a part of the shell-likestructural component is deflected when relative to attachment points ofthe shell-like structural component. For example, if two edges of theshell-like structural component are fixed by attachments or bearings,the deflection of the part of the shell-like structural component thatis between the attachments or bearings indicates the direction of thebending of the shell-like structural component. A similar case is shownin more detail in the description of the drawings.

According to another embodiment, a layered structure of the shell-likestructural component is generated by applying the first material to thesurface of the shell-like structural component. The layered structurecomprises a layer of the first material and the shell-like structuralcomponent.

The thickness of the layer of the first material may be the same atevery region on the surface of the shell-like structural component, butit may also vary such that different thicknesses of the layer of thefirst material occur at different regions on the surface of theshell-like structural component. There may also be more than one or twolayers of the first material. For example, there may be a plurality oflayers of the first material as well as a plurality of layers of theshell-like structural component such that the layered structure iscomposed by many different layers. However, layers of other materialsmay additionally be added to the layer of the first material and/or tothe shell-like structural component.

For example, the layer of the first material is applied to two differentsides, e. g. on the surfaces of the shell-like structural component suchthat the shell-like structural component is arranged between both layersof the first material. In this case, the first material is applied tothe shell-like structural component by heating both the shell-likestructural component and the first material. After cooling the layeredstructure comprising the shell-like structural component and the twolayers of first material, internal stresses may occur as a result ofdifferent thermal expansion characteristics of the first material andthe shell-like structural component. In other words, the first materialand the shell-like structural component may have different coefficientsof thermal expansion such that the first material contracts faster thanthe shell-like structural component and vice versa. In case the firstmaterial contracts faster than the shell-like structural component, thisis, the first material has a higher coefficient of thermal expansionthan the shell-like structural component, a tensile stress occurs withinthe first material whereas a compression stress occurs within theshell-like structural component. Such different coefficients of thermalexpansion of the different materials which are connected to each otherlead to tensile stresses or compression stresses which deform or bendthe shell-like structural component. Therefore, it is necessary thatthese materials are firmly connected.

According to another embodiment, the internal stress is induced usingdifferent materials.

For example, the shell-like structural component comprises anothermaterial than the first material which is applied to the shell-likestructural component. If both the first material and the shell-likestructural component comprise different coefficients of thermalexpansion, internal stresses may be generated within regions or nearregions to which the first material has been applied to the shell-likestructural component when the temperature changes. However, internalstresses may also be generated by adjusting the amount of first materialwhich is applied to the shell-like structural component. In other words,the more first material is applied to the shell-like structuralcomponent, the more the shell-like structural component will beinfluenced by the material characteristics of the first material.

According to another embodiment, the internal stress is induced usingdifferent temperatures when heating the region of the shell-likestructural component.

In other words, the different material characteristics of the shell-likestructural component and the other materials which are applied to theshell-like structural component may be influenced by a heat treatment.The heat treatment may be conducted such that only these parts orregions of the shell-like structural component are heated to which thefirst material is applied. Generally, the heat treatment using differenttemperatures or different materials provides the opportunity that aftercooling the shell-like structural component and the other materialsapplied to the shell-like structural component internal stresses aregenerated such that the bending of the shell-like structural componentitself or in combination with the first material is generated. The heattreatment or the arrangement of different materials at the shell-likestructural component may be adjusted such that a predetermined bendingof the shell-like structural component itself or in combination with thefirst material or other materials applied to the shell-like structuralcomponent can be achieved.

According to yet another embodiment, the shell-like structural componentis a floor panel. For example, the floor panel is installed in anaircraft as a passenger floor panel or a cargo floor panel.

After manufacturing the shell-like structural component, e.g. aftercooling the shell-like structural component, it may be assembled toother components as to form a part of a vehicle. The first material maytherefore be a part of the shell-like structural component. Aftermanufacturing the shell-like structural component, it comprises thefirst material since it is firmly bonded to the shell-like structuralcomponent. For example, the shell-like structural component is a floorpanel of the vehicle. The floor panel should have an even surface withno curvature, such as a plate. In a loaded condition, the floor panel isusually bent. This bending is defined by a deflection of parts of thefloor panel from a neutral line. By using the described manufacturingmethod, it is possible that the shell-like structural componentcomprises a predefined bending due to internal stresses such that thedeflection of the floor panel is directed into a direction which isopposite to a direction of a force in a loaded condition of the floorpanel. This means that the floor panel is deflected in an oppositedirection of the loading direction such that the deflection of the floorpanel is reduced or vanishes when the force is applied in a loadedcondition.

According to another embodiment, a thickness of the floor panel isbetween 2 millimeters and 4 millimeters. For example, the floor panel isintegrated in a cargo space or a passenger cabin.

Preferably, the thickness of the floor panel is 3 millimeters. The floorpanel may comprise different layers of material, e. g. a layeredstructure, but it may also comprise different alloys with differentmaterial characteristics, such as different coefficients of thermalexpansion.

According to another embodiment, the first material has a coefficient ofthermal expansion which differs from a coefficient of thermal expansionof at least the region of the shell-like structural component to whichthe first material has been applied.

Using materials with different coefficients of thermal expansiongenerates internal stresses after firmly bonding the materials andchanging the temperatures of the connected materials. In other words,both the first material and the shell-like structural component comprisedifferent coefficients of thermal expansion such that internal stressesare generated due to the different expansion characteristics of theshell-like structural component and the first material. This principlemay also be applied to various other materials which are combined to theshell-like structural component and/or the first material. Connecting orfirmly bonding two different materials each having an own coefficient ofthermal expansion, results in internal stresses occurring as tensilestresses and compression stresses.

According to another embodiment, the shell-like structural component isselected from the group comprising an aircraft cargo floor panel, a partof an aircraft outer skin, a part of an aircraft wing and a part of anaircraft door.

The cargo floor panel of the aircraft may have a thickness of preferably3 millimeters. The cargo floor panel may be deflected in an unloadedcondition due to the internal stresses generated within the shell-likestructural component such that, if the cargo floor panel is loaded, thedeflection may be significantly reduced or even vanish. This aspect willbe shown in more detail in the description of the drawings. The part ofthe outer skin of the aircraft may be connected to stringers or ribssuch that, in an unloaded condition, the part of the outer skin isdeflected in a region where there is no connection between the part ofthe outer skin and the ribs or stringers. Usually in flight, the innerpressure within the fuselage is higher than the outer pressure of theaircraft. This difference in pressure during cruise flight generates aforce which pushes the parts of the outer skin, which are not connectedto ribs or stringers, into the direction of the lower pressure, e.g.outwards or to the outside of the aircraft. Using the shell-likestructural component of the described manufacturing method, results in abending or deflection of the part of the outer skin in the directionopposite to the direction into which the part of the outer skin ispushed due to the pressure loads. This reduces the deflection of thepart of the outer skin. In this manner, the aerodynamic characteristicsof the outer skin of an aircraft may be positively influenced since nodeflections or reduced deflections at the outer skin occur. The sameapplies to an aircraft door, which means that the aircraft door isdeflected due to internal stresses such that, in a loaded condition, forexample during flight, the aircraft door adapts an ideal form, e.g. theaircraft door may be aligned with the outer skin of the aircraft.Furthermore, an aircraft wing is bent or deflected in a loadedcondition. This means that the deflection of the aircraft wing duringflight differs from the deflection of the aircraft wing during groundoperation. By a bending or a deflection which is opposite to the loadingdirection of the wings during flight, improved flight characteristicscan be achieved, for example a reduced aircraft drag. The deflectionwhich is opposite to the loading direction of the wing may be induced byinternal stresses generated within the part of the aircraft wing, e. g.the parts of the wing to which the shell-like structural component hasbeen attached. This is also explained in more detail in the descriptionof the drawings. If within the description the word “ideal” is used, itmay refer to advantageous mechanical or aerodynamic characteristicsbeing achieved by the adaption of certain shapes or contours. Thus, itmay mean that certain mechanical or aerodynamic characteristics orbehaviors of components of the vehicle may be enhanced.

According to yet another embodiment, the first material is selected fromthe group comprising silicon, ion, copper, manganese, chromium, tin,vanadium, titanium, bismuth, gallium, lead, aluminum and zirconium.

Furthermore, synthetic materials may also be used for the first materialand/or the shell-like structural component. Alloys comprising differentmetallic or non-metallic materials may also be a suitable compositionfor the first material and/or the shell-like structural component. It ispossible to use multiple metal or plastic materials for themanufacturing or printing process to create a shell-like structuralcomponent which comprises different metal or plastic alloys to generatethe needed specific properties at each location of the shell-likestructural component. The needed alloy is produced or generated duringthe three-dimensional printing process. It should be noted that theadditive manufacturing of the shell-like structural component may alsobe called printing process since the first material is added to theshell-like-structural component in order obtain the ready-madeshell-like structural component which comprises the first material.

According to another embodiment, the first material may be applied tothe surface of the shell-like structural component such that anextrusion protruding on the surface of the shell-like structuralcomponent, e. g. a protrusion on the surface of the shell-likestructural component is provided. These protrusions may be manufacturedfrom a synthetic material.

Moreover, the protrusions itself may comprise different materials whichare applied to the surface of the shell-like structural component. Thematerial or materials may be applied such that a fiber-reinforced body,for example on the surface of the shell-like structural component, isgenerated. Therefore, metal fibers or carbon fibers may be used tostrengthen or reinforce a matrix material, like for instance plastics.These fiber reinforced materials which are applied or printed to thesurface of the shell-like structural component may reduce crackpropagation within the shell-like structural component. In other words,the fiber-reinforced protrusions may effectively prevent a furtheropening of the crack surfaces. Furthermore, theses protrusions may havean arbitrarily shaped cross-section, wherein the cross-section isobtained ether tangentially or perpendicularly to the surface of theshell-like structural component. An arbitrary cross-section of theprotrusions may be obtained using printing process like selective lasermelting and/or additive layer manufacturing.

Additionally, the integrated fibers induce a thermal tensioning orstress within the shell-like structural component due to the differentcoefficients of thermal expansion of the different materials such that acrack initiation is avoided. In other words, the integrated fibersinduce an inherent compressing stress which is induced by differentthermal expansions of the different fiber materials and/or differentmatrix materials.

According to another embodiment, the first material is applied to theshell-like structural component in a fibrous form. For example, theprotrusions may comprise high-strength fibers. Such protrusions,especially those comprising fibers, may provide an enhanced fatigue anddamage tolerance.

According to another embodiment, the shell-like structural componentsare used as stiffening means. Such stiffening means may be used tostrengthen certain parts of an aircraft fuselage, for example corners ofa door frame. In this manner, shell-like structural components may beused at the corners of a door of an aircraft fuselage such thatso-called corner doublers, which are usually integrated at said corners,may be replaced. The stiffening of the corners may be provided byinduced internal stresses within the shell-like structural componentsleading to an improved fatigue and damage tolerance. The shell-likestructural component may be attached near the door of the aircraft, e.g. at the corners of the door.

According to another embodiment, a stress within the shell-likestructural component is generated by shot-peening and flare fitting.Shock-peening is understood as a working process used to produce acompressive residual stress layer and modify mechanical properties incomponents. In this manner, the mechanical properties of the shell-likestructural component may locally be influenced so as to enhance thedurability and robustness of the shell-like structural component. Thestresses generated by flare-fitting may also result in an improvement ofthe durability and the mechanical robustness of the shell-likestructural component. Flare fitting is a working process using a mandrelthat is forced into the end of a hole or a tube-like element in order toform a flare by cold working. For example such holes may be placedwithin the shell-like structural component. Flare-fitting generatesstresses in a region around or near the holes or tube-like elements ofthe shell-like structural component such that the stresses enhance thedurability or robustness in these regions. It should be mentioned thatshock-peening and flare-fitting may also be used in order to generate astress within components, e. g. the shell-like structural component,such that these components adapt a predetermined shape as a result ofthe internal stresses. The adaption of a predetermined shape may occuras a bending of the component.

According to another aspect, an internal stress exists within theshell-like structural component for an aircraft which results in abending of the shell-like structural component. A bending direction ofthe shell-like structural component is opposite to a direction of aforce which acts on the shell-like structural component when it isinstalled in the vehicle. The force is generated by a cargo unitstanding on the shell-like structural component or by cabin airpressure. The internal stress which exists within the shell-likestructural component may be induced by a working process like additivelayer manufacturing, selective laser melting, shock-peening or flarefitting.

According to another aspect, a use of a shell-like structural componenton an aircraft is provided.

BRIEF DESCRIPTION OF THE DRAWINGS

The various embodiments will hereinafter be described in conjunctionwith the following drawing figures, wherein like numerals denote likeelements, and:

FIG. 1 shows a cross-sectional view of a layered structure withdifferent materials according to an embodiment.

FIG. 2 shows a cross-sectional view of a layered structure withdifferent thicknesses of the layers according to an embodiment.

FIG. 3 shows a cross-sectional view of a layered structure which isdeformed as a result of internal stresses within the layered structureaccording to an embodiment.

FIG. 4 shows s sectional view of a shell-like structural component in anunloaded condition and in a loaded condition according to an embodiment.

FIG. 5A shows a sectional view of stiffening units and a part of anouter skin of an aircraft fuselage in an unloaded condition according toan embodiment.

FIG. 5B shows a sectional view of stiffening units and a part of anouter skin of an aircraft fuselage in a loaded condition according to anembodiment.

FIG. 6A shows a cross-sectional view of an aircraft fuselage with anintegrated aircraft door in an unloaded condition according to anembodiment.

FIG. 6B shows a cross-sectional view of an aircraft fuselage with anintegrated aircraft door in a loaded condition according to anembodiment.

FIG. 7A schematically shows an aircraft with aircraft wings in anunloaded and in a loaded condition according to an embodiment.

FIG. 7B schematically shows another aircraft with aircraft wings in anunloaded and in a loaded condition according to an embodiment.

FIG. 8A schematically shows a side view of an aircraft fuselage in anunloaded condition according to an embodiment.

FIG. 8B schematically shows a side view of an aircraft fuselage in aloaded condition according to an embodiment.

FIG. 8C schematically shows a side view of an aircraft fuselage in anunloaded condition according to another embodiment.

FIG. 9 shows a flow diagram for a method for manufacturing a shell-likestructural component for a vehicle using additive layer manufacturing.

DETAILED DESCRIPTION

The following detailed description is merely exemplary in nature and isnot intended to limit the disclosed embodiments or the application anduses thereof. Furthermore, there is no intention to be bound by anytheory presented in the preceding background detailed description.

Items shown in the Figures are not drawn to scale. In FIG. 1 across-sectional view of a layered structure 10 with different layers ofmaterial is shown. The layered structure 10 may be at least a part of ashell-like structural component, which shell-like structural componentmay be used in a vehicle such as an aircraft, a car or a rail vehicle.The shell-like structural component may thus be a part of an outer skinof an aircraft, a floor panel of an aircraft or a part of a door of anaircraft. The layered structure 10, which is shown in FIG. 1, comprisesthree different material layers. For example, a first layer 1 and athird layer 3 are made of the same material and a second layer 2 whichis arranged between the first layer 1 and the third layer 3 is made of amaterial that is different from the material of the first layer 1 andthe third layer 3. The material of the first layer 1 and the third layer3 may be aluminum and the material of the second layer 2 may betitanium. As shown in FIG. 1, the geometrical dimensions of the firstlayer 1 and the third layer 3 are identical such that a symmetricalimpression of the composition of the layered structure 10 may beobtained. The layered structure 10 may be manufactured by additive layermanufacturing and/or selective laser melting such that, after connectingthe different layers of the layered structure 10, a metallic continuitybetween the layers can be achieved; e. g. the different layers may befirmly bonded. When changing the temperature of the layered structure10, e. g. when cooling the layered structure 10 after the manufacturingprocess, internal stresses are generated within the layered structure 10because titanium and aluminum have different coefficients of thermalexpansion. In other words, titanium has a smaller thermal expansion orelongation than aluminum when equally changing the temperature of bothmaterials which leads to internal stresses within every layer of thelayered structure 10.

FIG. 2 shows cross-sectional view of a layered structure 10 with anunsymmetrical design in which the first layer 1 is thicker than thethird layer 3. In this example the first layer 1 and the third layer 3are made of aluminum and the second layer 2, which is located betweenthe first layer 1 and the third layer 3, is made of titanium. Thelayered structure 10 may as well be manufactured using additive layermanufacturing and/or selective laser melting such that a metalliccontinuity is provided between the first layer 1 and the second layer 2as well as between the second layer 2 and the third layer 3. However,the different layers may be firmly bonded. In this manner, it ispossible that a internal stress within the layered structure 10 isinduced or generated if the temperature of the layered structure 10 ischanged. This is due to the different coefficients of thermal expansionor the expansion characteristics of different materials. In this case,titanium has a lower coefficient of thermal expansion than aluminum.

As a result of the induced internal stresses, the layered structure 10may be deformed, as shown in FIG. 3. The deformation may appear as abending or twisting of the layered structure 10. The cross-sectionalview in FIG. 3 indicates a bending of the layered structure 10. Thebending is generated by internal stresses being induced by the firmlybonded arrangement of layers of the layered structure 10 combined withchanges in temperature to which the layered structure 10 is subjected.For example, the layered structure 10 is not bent when it ismanufactured by additive layer manufacturing at relatively hightemperatures whereas a bending, as shown in FIG. 3, occurs when coolingthe layered structure 10 to environmental conditions. In this case, thefirst layer 1 is thicker than the second layer 2 and the third layer 3.The unsymmetrical arrangement of the different layers may induceinternal stresses within the layered structure 10 and the occurrence ofinternal stresses in turn results in the bending visualized in FIG. 3.By the method for manufacturing the shell-like structural componentusing additive layer manufacturing, a predetermined bending of thelayered structure 10 may be achieved such that a predetermineddeflection as a result of the bending of the layered structure 10 isprovided. This deflection may advantageously compensate a deformationwhich is due to external loads.

FIG. 4 shows a sectional view of a shell-like structural component in aloaded condition 21 and in an unloaded condition 20, wherein theshell-like structural component is attached to two beams 23 a, 23 b. Afirst end of the shell-like structural component is attached to a firstbeam 23 a and a second end of the shell-like structural component isattached to a second beam 23 b. It should be mentioned that the itemsshown in FIG. 4 are three-dimensional objects, like for instance a cargofloor panel that is supported by two beams 23 a, 23 b. The beams, whichare also called cross beams, may be extruded aluminum profiles connectedby friction stir welding. A front view of this arrangement is chosen forsimplicity. In the unloaded condition 20, the shell-like structuralcomponent is bent in such a way that at least a part of it is deflectedinto a first direction 24 which indicated by an arrow. Thus the firstdirection 24 indicates the bending direction. This bending is due tointernal stresses induced by providing different materials within acertain region or certain regions of the shell-like structural componentwhich for instance comprises a layered structure. If an external load isapplied to the shell-like structural component in a second direction 22which is indicated by another arrow, the shell-like structural componentis pushed into the second direction 22 opposite to the first direction24. In other words the bending direction 24 is substantially paralleland/or opposite to the loading direction 22. However, in the loadedcondition 21, the deflection or bending of the shell-like structuralcomponent may be reduced. The loaded condition 21 visualized in FIG. 4indicates that the bending or the deflection of the shell-likestructural component may even vanish if a distinct load is reached. Theinternal stresses may be induced within the shell-like structuralcomponent such that a predetermined bending or deflection occurs when acertain force or load is applied to the shell-like structural componentin the loaded condition 21. In other words, the internal stresses withinthe shell-like structural component and hence the bending of theshell-like structural component may be adapted by using the describedmanufacturing method. Applying the first material to well-chosen regionsof the shell-like structural component by additive layer manufacturing,provides the possibility to predetermine the deformation and with it thebending of the shell-like structural component with respect to changesof environmental conditions, such as pressure differences or temperaturedifferences. Therefore, the shell-like structural component may adopt ashape which provides enhanced operating conditions of the vehicle intowhich the shell-like structural component is integrated.

FIG. 5A shows sectional view of two stiffening units 32 and a part of anouter skin 30 of an aircraft fuselage in an unloaded condition 20 andFIG. 5B shows the same in a loaded condition 21. For simplicity, thestiffening units 32 are drawn as if they are detached from the outerskin 30. In a ready-made aircraft fuselage, the stiffening units 32 areattached to the outer skin 30. The stiffening units 32 may be stringersor ribs. The part of the outer skin 30 may be the shell-like structuralcomponent which is manufactured by the described method. In the unloadedcondition 20 the shell-like structural component is bent or deformedsuch that a corrugated shape is adopted. This corrugated shape is theresult of the internal stresses induced by the manufacturing process ofthe shell-like structural component. An ideal contour 31 is also shownin FIG. 5A. The ideal contour 31 describes a condition of the part ofthe outer skin 30 which is characterized by a reduced drag during flightof the aircraft. This ideal contour 31 is adopted by the part of theouter skin 30 in the loaded condition 21 which is described in FIG. 5B.The pressure difference between the inside of the aircraft fuselage andthe outside of the aircraft fuselage during cruise flight causes a loadon the part of outer skin 30 such that a linear shape of the part of theouter skin 30 is adapted. The part of the outer skin 30 maysubstantially be aligned with the ideal contour 31 such that, in aloaded condition 21, a reduced drag can be achieved. Generally, thedeformation of the part of the outer skin 30, which may be theshell-like structural component, may be generated by internal stresseswithin the part of the outer skin 30 induced by the described methodsuch that the part of the outer skin 30 adopts an aerodynamicallyimproved shape if a certain pressure difference or temperature change isreached; e. g. the part of the outer skin 30 follows the ideal contour31.

FIG. 6A shows a cross-sectional view of an aircraft fuselage with anintegrated aircraft door 40 in an unloaded condition 20. Moreover, afloor 43 within the aircraft fuselage as well as an outer skin 41 of theaircraft fuselage is indicated. The aircraft door 40 may be theshell-like structural component which is manufactured by the describedmethod. The door 40 may be slightly bent in the unloaded condition 20 asshown in FIG. 6A. It is noted that the illustration of the shape of thedoor is strongly exaggerated. The door 40 may be manufactured by themethod, such that, if a predetermined load is applied to the door 40 ina loaded condition 21, it is deformed or bent and thereforesubstantially aligned with the contour of the outer skin 41 of theaircraft fuselage. The loaded condition 21 is shown in thecross-sectional view of FIG. 6B. In the loaded condition 21 the door 40is pushed from the inside towards the outside with respect to theaircraft fuselage. This may positively influence the aerodynamiccharacteristics of the aircraft in a region near the door 40. Theprinciple may generally apply to other structural components of anaircraft, such as a pressure bulkhead. It should be understood that theinside of an aircraft fuselage describes the part of an aircraft whichis enclosed by the surrounding outer skin 41 whereas the outsidedescribes the environment surrounding the outer skin 41 or the aircraftfuselage.

FIG. 7A schematically shows a first aircraft 50 with aircraft wings inan unloaded condition 20 and in a loaded condition 21. The firstaircraft 50 may be a conventional passenger aircraft. In the unloadedcondition 20, e. g. during ground operation, the wings of the firstaircraft 50 may adapt the shape indicated by the dashed lines in FIG.7A. This shape represents an ideal contour which is provided byconventionally manufacturing or assembling the aircraft wings. In theloaded condition 21, e. g. during cruise flight, the wings of the firstaircraft 50 are bent or deflected in a vertical direction of the firstaircraft 50 such that a deviation from the ideal contour is caused.

In contrast, FIG. 7B schematically shows a second aircraft 51 withaircraft wings in an unloaded condition 20 and in a loaded condition 21,the wings being manufactured by the method according to the embodiment.Therefore, shell-like structural components may be integrated into thewings such that, in the unloaded condition 20, e. g. during groundoperation, a bending or deflection of the wings is generated as a resultof internal stresses generated by the manufacturing method. The shape orcontour of the wings in the unloaded condition 20 is indicated by dashedlines in FIG. 7B. In the loaded condition 21 of the wings of the secondaircraft 51, e. g. during cruise flight, the wings may adapt a shapewhich is substantially equal to the ideal contour. The adaption may besupported by a bending or deflection which is caused by temperaturedifferences between ground operation and cruise flight. The bending maybe significantly influenced by temperature differences since theshell-like structural components may comprise different materials, eachhaving distinct coefficients of thermal expansion. In other words, thewings may substantially be adapted to the ideal contour with minimumdrag if a certain load in combination with a certain temperature isreached during cruise flight. Adapting the ideal contour of the wings inthe loaded condition 21, results in a drag count reduction during cruiseflight of the second aircraft 51. This principle may also be used forother applications in which a deformation and bending of shell-likestructural components, which are integrated in a vehicle, leads toenhanced aerodynamic characteristics.

For example, FIG. 8A schematically shows a side view of an aircraftfuselage in an unloaded condition 20. The unloaded condition 20, e. g.during ground operation, is characterized by an ideal contour or shapeof the fuselage which would provide a good aerodynamic behavior of thefuselage. This ideal contour or shape is usually not existent anymoreduring flight since the aircraft fuselage becomes deformed due toexternal loads, as shown in FIG. 8B. The external loads may for instancebe lift forces predominantly acting on the wings. The external loadschange the shape of the whole fuselage. This deformation of the fuselagemay result in a reduced aerodynamic efficiency. However, the embodimentprovides a method for manufacturing shell-like-structural componentswhich may be integrated into the aircraft fuselage, for example as partsof the outer skin 30, such that a deformation or bending of the fuselagein an unloaded condition 20 is generated. This aspect is visualized inFIG. 8C, which shows the aircraft fuselage in an unloaded condition 20,for example after assembling the fuselage on the ground. The generatedbending in the unloaded condition 20 may lead to an adaption of thefuselage shape to said ideal contour or shape, as shown in FIG. 8A, inthe loaded condition 21. The aerodynamic efficiency in the loadedcondition 21, e. g. during flight, may be enhanced by the adaption ofthe fuselage to the ideal shape. Adaption of the ideal contour or shapemeans that the induced bending of the fuselage after assembling on theground is reduced during flight operation.

FIG. 9 shows a method for manufacturing a shell-like structuralcomponent for a vehicle using additive layer manufacturing and/orselective laser melting. The method comprises different steps. In a stepS1 of the method, a first material is applied to a region of theshell-like structural component. In another step S2, the region of theshell-like structural component is heated by a laser beam such that thefirst material is added to the shell-like structural component. Forexample, a powder bed on the shell-like structural component is heatedbefore applying or printing the first material to the shell-likestructural component. The shell-like structural component whichcomprises the first material is cooled in another step S3 such that aninternal stress is generated within the shell-like structural componentresulting in a bending of the shell-like structural component. Themethod may comprise further steps, like for instance changing atemperature and/or a pressure difference such that the shell-likestructural component adopts a predetermined geometrical shape.

Applying the first material to the region of the shell-like structuralcomponent may be conducted in a multi-direction additive manufacturingprocess in which the first material is simultaneously applied fromdifferent directions and/or to different regions of the shell-likestructural component. This provides an accelerated manufacturing of theshell-like structural component.

It should be understood that the first material may be applied onto thesurface of the shell-like structural component as well as into theshell-like structural component. Thus, it is also possible that thefirst material is enclosed by the shell-like structural component, forexample in a layered structure. In other words, the first material iscomprised by the shell-like structural component.

The method also provides an additive repair process for filling dents orscratches on the surface of the shell-like structural component. Thedents or scratches may be filled with Scalmalloy which is an alloycomprising aluminum, magnesium and scandium. Thus, it may not benecessary that the material on the surface of the shell-like structuralcomponent has to be removed or scraped by subtractive processes untilthe dents or scratches vanish.

While the embodiments have been illustrated and described in detail inthe drawings and the foregoing description, such illustration anddescription are to be considered illustrative and exemplary and notrestrictive; the embodiments are not limited to the disclosedembodiments. Other variations to the disclosed embodiments can beunderstood and effected by those skilled in the art and practicing theclaimed embodiment, from a study of the drawings, the disclosure, andthe appended claims. In the claims the term “comprising” does notexclude other elements, and the indefinite article “a” or “an” does notexclude a plurality. The mere fact that certain measures are recited inmutually different dependant claims does not indicate that a combinationof these measures cannot be used to advantage. Any reference signs inthe claims should not be construed as limiting the scope of protection.

While at least one exemplary embodiment has been presented in theforegoing detailed description, it should be appreciated that a vastnumber of variations exist. It should also be appreciated that theexemplary embodiment or exemplary embodiments are only examples, and arenot intended to limit the scope, applicability, or configuration of theembodiment in any way. Rather, the foregoing detailed description willprovide those skilled in the art with a convenient road map forimplementing an exemplary embodiment, it being understood that variouschanges may be made in the function and arrangement of elementsdescribed in an exemplary embodiment without departing from the scope ofthe embodiment as set forth in the appended claims and their legalequivalents.

What is claimed is:
 1. A method for manufacturing a shell-likestructural component for a vehicle using additive layer manufacturing,comprising: applying a first material to a region of the shell-likestructural component; heating the region of the shell-like structuralcomponent by a laser beam such that the first material is added to theshell-like structural component; and cooling the shell-like structuralcomponent comprising the first material, such that an internal stress isgenerated within the shell-like structural component resulting in abending of the shell-like structural component; wherein internalstresses are induced within the shell-like structural component suchthat a predetermined bending occurs when a certain force or load isapplied to the shell-like structural component in a loaded condition;and wherein the internal stress is induced using different temperatureswhen heating the region of the shell-like structural component.
 2. Themethod according to claim 1, further comprising: applying the firstmaterial to a plurality of regions of the shell-like structuralcomponent from different directions.
 3. The method according to claim 1,wherein a bending direction is opposite to a direction of a force whichacts on the shell-like structural component when it is installed in thevehicle, wherein the force is generated by a cargo unit standing on theshell-like structural component or by cabin air pressure.
 4. The methodaccording to claim 1, further comprising: generating a layered structureof the shell-like structural component by applying the first material tothe surface of the shell-like structural component, wherein the layeredstructure comprises a layer of the first material.
 5. The methodaccording to claim 1, wherein the internal stress is induced usingdifferent materials.
 6. The method according to claim 1, wherein theshell-like structural component is a floor panel.
 7. The methodaccording to claim 6, wherein a thickness of the floor panel is between2 millimeters and 100 millimeters, preferably between 2 millimeters and4 millimeters.
 8. The method according to claim 1, wherein the firstmaterial has a coefficient of thermal expansion which differs from acoefficient of thermal expansion of the region of the shell-likestructural component to which the first material is applied.
 9. Themethod according to claim 1, wherein the shell-like structural componentis selected from the group comprising an aircraft cargo floor panel, apart of an aircraft outer skin, a part of an aircraft wing and a part ofan aircraft door.
 10. The method according to claim 1, wherein the firstmaterial is selected from the group comprising silicone, iron, copper,manganese, chromium, tin, vanadium, titanium, bismuth, gallium, lead,aluminum and zirconium.
 11. A method for manufacturing a shell-likestructural component for a vehicle using additive layer manufacturing,comprising: applying a first material to a region of the shell-likestructural component; heating the region of the shell-like structuralcomponent by a laser beam such that the first material is added to theshell-like structural component; and cooling the shell-like structuralcomponent comprising the first material, such that an internal stress isgenerated within the shell-like structural component resulting in abending of the shell-like structural component; wherein internalstresses are induced within the shell-like structural component suchthat a predetermined bending occurs when a certain force or load isapplied to the shell-like structural component in a loaded condition;and wherein additional internal stress is generated within theshell-like structural component by shot-peening and flare-fitting.
 12. Amethod for manufacturing a shell-like structural component for a vehicleusing additive layer manufacturing, the method comprising the steps of:performing a multi-direction additive manufacturing process to print afirst material on a first surface of the shell-like structural componentand to simultaneously print the first material on a second surface ofthe shell-like structural component, resulting in a layered structure;heating regions of the shell-like structural component by a laser beamsuch that the first material is added to the shell-like structuralcomponent; and cooling the shell-like structural component comprisingthe first material to generate an internal stress within the shell-likestructural component, resulting in a bending of the shell-likestructural component in an unloaded condition; wherein internal stressesare induced within the shell-like structural component such that apredetermined bending occurs when a certain force or load is applied tothe shell-like structural component in a loaded condition.